Apparatus and method for automated handle installation

Abstract

Embodiments of the present invention relate to an apparatus and method for high speed automated installation or attachment of preformed handles onto portable containers such as buckets, boxes, cartons, or pails that are moving on a conveyor system through the apparatus. A frame structure supports the apparatus. A container conveyor conveys the portable containers into and out of the apparatus. A handle sheet conveyor conveys sheets of preformed handles from storage containers into a handle magazine. Individual handles are detached from the preformed handle sheets, after which the handles are attached onto the portable containers at a high rate of speed. A slidable handle separation and insertion mechanism includes a main slide for preforming the handles prior to insertion onto the portable containers. In some embodiments the main slide is angled at approximately a 45 degree angle from the horizontal.

What is claimed is: 
     
       1. A handle attachment apparatus, said apparatus comprising:
 a frame; 
 a conveyor for portable containers; 
 a sheet picker; 
 a handle sheet magazine; 
 a slidable fixture; 
 a detachment mechanism configured to detach preformed handles from handle sheets; and 
 an attachment mechanism configured to attach said preformed handles onto connection points of said portable containers; 
 wherein said slidable fixture is mounted at a 45 degree angle from horizontal. 
 
     
     
       2. The apparatus of  claim 1 , wherein said conveyor further comprises:
 a plurality of differential speed movable tracks configured to convey and rotate said portable containers; and 
 at least one ear rail configured to accept a plurality of ears attached to outer surfaces of said portable containers. 
 
     
     
       3. The apparatus of  claim 1 , wherein said sheet picker comprises:
 a storage area for handle sheets; 
 a pickup arm; 
 a pickup plate attached to a proximal end of said pickup arm; 
 pickup jaws attached to said pickup arm; and 
 sensors to detect positions of said handle sheets. 
 
     
     
       4. The apparatus of  claim 3 , further including:
 at least one horizontal track; 
 at least one vertical track; and 
 whereby said pickup arm moves along said horizontal track and along said vertical track proximate to said sheet containers and proximate to said handle sheet magazine. 
 
     
     
       5. The apparatus of  claim 1 , wherein said handle sheet magazine comprises a substantially rectangular tray configured to contain at least one handle sheet. 
     
     
       6. The apparatus of  claim 1 , further including:
 a plurality of cutting blades extending from said detachment mechanism and configured to detach single preformed handles from said handle sheets. 
 
     
     
       7. The apparatus of  claim 1 , further including: a plurality of projecting arms extending from said slidable fixture; and channels on the proximal ends of said projecting arms configured to enclose a single preformed handle. 
     
     
       8. The apparatus of  claim 7 , further including: an anvil mounted proximate to the distal ends of said projecting arms; clamp cylinders configured to constrain a single preformed handle against said anvil; and a plurality of plungers; whereby said plungers insert the ends of a preformed handle onto said connection points of a portable container. 
     
     
       9. The apparatus of  claim 1 , further including:
 a plurality of substantially parallel fixture rails; wherein said slidable fixture is configured to slide on said parallel fixture rails. 
 
     
     
       10. A method for attaching preformed handles onto portable containers, said method comprising the steps of:
 conveying portable containers proximate to an apparatus, said portable containers having ears with connection points attached on their outer surfaces; 
 conveying handle sheets into a handle sheet magazine; 
 providing a slidable fixture so that said slidable fixture is mounted at a 45 degree angle from horizontal; 
 providing projecting arms at the distal ends of said slidable fixture; 
 detaching preformed handles from said handle sheets; 
 constraining said preformed handles within said projecting arms; and 
 attaching said preformed handles onto said connection points on said portable containers. 
 
     
     
       11. The method of  claim 10 , further comprising the steps of:
 conveying said portable containers on a plurality of differential speed movable tracks; and 
 rotating said portable containers so that said ears are perpendicular to a direction of movement of said portable containers. 
 
     
     
       12. The method of  claim 10 , wherein the step of conveying handle sheets further comprises the steps of:
 providing at least one horizontal track; 
 providing at least one vertical track; and 
 moving a pickup arm along said horizontal track and along said vertical track; 
 whereby said handle sheets are conveyed from a storage area into said handle sheet magazine. 
 
     
     
       13. A method for attaching a preformed handle onto a portable container comprising:
 conveying the portable container proximate to an apparatus, 
 wherein each portable container comprises:
 a first connection point on a first exterior side of the portable container; and 
 a second connection point on a second exterior side of the portable container opposite the first side; 
 
 conveying a handle sheet into a handle sheet magazine; 
 constraining a first end and a second end of a preformed handle of the handle sheet using projecting arms of a slidable fixture, 
 wherein the first end has a first connector and the second end has a second connector; 
 detaching the preformed handle from the handle sheet; 
 drawing the preformed handle over a mandrel using the slidable fixture so that the preformed handle forms a u-shape; 
 extending plungers against the first end and the second end to attach the first connector to the first connection point and the second connector to the second connection point.